Genie GRC-12 Service Manual
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Genie GRC-12 Service Manual

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Service Manual
GRC -12
Serial Number Range
from GRC11-1000
to GRC16-2369
from GRC16P-2370
to GRC16P-4599
from GRCP-4600
Part No. 227123
Rev B1
September 2016

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Summary of Contents for Genie GRC-12

  • Page 1 Service Manual Serial Number Range GRC -12 from GRC11-1000 to GRC16-2369 from GRC16P-2370 to GRC16P-4599 from GRCP-4600 Part No. 227123 Rev B1 September 2016...

  • Page 2: Introduction

    September 2016 Introduction Important Serial Number Information Read, understand and obey the safety rules and Genie offers the following Service Manuals for this operating instructions in the appropriate Operator's model: Manual on your machine before attempting any Title Part No.

  • Page 3: Serial Number Legend

    September 2016 INTRODUCTION Serial Number Legend To August 31, 2016 GRC 16 P - 1234 GRC16P-1234 Model: Serial number: 01/02/2010 2016 Manufacture date: Model year: Elec/Hydr Schematic: Power supply voltage/Pneumatic Pressure: Nominal Power: Machine unladen weight: Max Load: Occupants and Equipment must not exceed: Maximum allowable inclination of the chassis: Maximum Wind Speed: Indoor:...

  • Page 4: September 2016

    September 2016 This page intentionally left blank. Part No. 227123...

  • Page 5: Safety Rules

    September 2016 Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operator’s manual are also safety hazards when maintenance and repair procedures are performed.

  • Page 6: September 2016

    September 2016 SAFETY RULES Personal Safety Workplace Safety Any person working on or around a machine must Be sure to keep sparks, flames and be aware of all known safety hazards. Personal lighted tobacco away from flammable and safety and the continued safe operation of the combustible materials like battery gases machine should be your top priority.

  • Page 7: Table Of Contents

    September 2016 Table of Contents Introduction Important Information ..................ii Serial Number Information ................. ii Serial Number Legend ..................iii Section 1 Safety Rules General Safety Rules ..................v Section 2 Specifications Machine Specifications ................2 - 1 Performance Specifications ................. 2 - 2 Hydraulic Specifications ................
  • Page 8 September 2016 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures, continued Checklist B Procedures B-1 Inspect the Batteries ................3 - 9 B-2 Inspect the Electrical Wiring ............. 3 - 12 B-3 Inspect the Tires and Wheels (including castle nut torque) ....3 - 13 B-4 Test the Emergency Stop ..............
  • Page 9 September 2016 TABLE OF CONTENTS Section 4 Repair Procedures Introduction ....................4 - 1 Platform Controls Circuit Board ..................4 - 3 Joystick ....................4 - 4 Platform Controls Alarm ..............4 - 4 Platform Emergency Stop Button ............4 - 5 Ground Controls Software Revision Level ..............
  • Page 10 September 2016 TABLE OF CONTENTS Section 4 Repair Procedures, continued Hydraulic Tank Hydraulic Tank ................. 4 - 23 Steer Axle Components Yoke and Drive Motor ..............4 - 24 Steer Cylinder .................. 4 - 26 Steer Bellcrank ................. 4 - 26 Non-steer Axle Components Drive Brake ..................
  • Page 11 September 2016 Section 5 Diagnostics Introduction ....................5 - 1 GCON I/O Map .................... 5 - 3 Operational Indicator Codes ................ 5 - 4 Diagnostic Indicator Codes ................5 - 4 Troubleshooting "HXX" and "PXXX" Faults ..........5 - 5 Fault Inspection Procedure ................

  • Page 12: Part

    September 2016 This page intentionally left blank. Part No. 227123...

  • Page 13: Machine Specifications

    September 2016 Section 2 • Specifications Specifications REV B Machine Specifications Height, stowed maximum GRC-12 66.8 in Batteries, Standard 1.69 m Voltage 6V DC Tires and wheels Group Tire size (solid rubber) 10 x 3 in 25.4 x 7.62 cm...

  • Page 14: Performance Specifications

    1.8 km/h Chevron Rykon MV oil is fully compatible and 12.2 m / 24.8 sec mixable with Shell Donax TG (Dexron III) oils. Genie specifications require hydraulic oils which are Platform raised 0.5 mph designed to give maximum protection to hydraulic...

  • Page 15: Manifold Component Specifications

    September 2016 Section 2 • Specifications REV B SPECIFICATIONS Manifold Component Function pump Specifications Type Gear Displacement per revolution 0.244 cu in Plug torque 4 cc SAE No. 2 50 in-lbs / 6 Nm Flow rate @ 2500 psi / 172 bar 4 gpm SAE No.

  • Page 16: Hydraulic Hose And Fitting Torque Specifications

    Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with JIC 37° flared fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed.
  • Page 17 September 2016 Section 2 • Specifications REV B SPECIFICATIONS Torque Procedure 3 Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to JIC 37° fittings indicate the proper tightening position. Refer to Figure 2. 1 Align the tube flare (hex nut) against the nose of Use the JIC 37°...
  • Page 18 Section 2 • Specifications September 2016 SPECIFICATIONS REV B SAE FASTENER TORQUE CHART • This chart is to be used as a guide only unless noted elsewhere in this manual • A574 High Strength Grade 5 Grade 8 SIZE THREAD Black Oxide Bolts LUBED LUBED...

  • Page 19: Observe And Obey

    Use only Genie approved replacement parts. Indicates a potentially hazardous Machines that have been out of service for a situation which, if not avoided, period longer than 3 months must complete the may result in property damage.

  • Page 20: Pre-Delivery Preparation Report

    Section 3 • Scheduled Maintenance Procedures September 2016 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Pre-delivery Preparation Report Note: The following symbols have been used in The pre-delivery preparation report contains this manual to help communicate the intent of the checklists for each type of scheduled inspection. instructions.
  • Page 21 The Maltings, Wharf Road PO Box 1150 Grantham, Lincolnshire Watertown, SD 57201-6150 NG31- 6BH England (605) 882-4000 (44) 1476-584333 Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South Dakota, Inc. 133192 Rev D Part No. 227123 3 - 3...
  • Page 22 Section 3 • Scheduled Maintenance Procedures September 2016 This page intentionally left blank. 3 - 4 Part No. 227123...

  • Page 23: Maintenance Inspection Report

    September 2016 Section 3 • Scheduled Maintenance Procedures Maintenance Inspection Report REV B Model Checklist A - Rev A Y N R Checklist B - Rev B Y N R A-1 Inspect the manuals B-1 Batteries Serial number and decals B-2 Electrical wiring A-2 Pre-operation B-3 Tires and wheels...

  • Page 24: Checklist A Procedures

    They also Note: Contact your authorized Genie distributor or provide users with operation and maintenance Genie if replacement manuals or decals are information. An illegible decal will fail to alert needed.

  • Page 25: Perform Pre-Operation Inspection

    September 2016 Section 3 • Scheduled Maintenance Procedures REV A CHECKLIST A PROCEDURES Perform Pre-operation Inspection Perform Function Tests Completing a Pre-operation Inspection is essential Completing the function tests is essential to safe to safe machine operation. The Pre-operation machine operation. Function tests are designed to Inspection is a visual inspection performed by the discover any malfunctions before the machine is operator prior to each work shift.

  • Page 26: Perform 30 Day Service

    Perform 30 Day Service Grease the Steer Yokes The 30 day maintenance procedure is a one time Genie specifications require that this procedure be procedure to be performed after the first 30 days or performed every 100 hours of operation.

  • Page 27: Checklist B Procedures

    Section 3 • Scheduled Maintenance Procedures Checklist B Procedures REV B Inspect the Batteries Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper battery condition is essential to good machine performance and operational safety.
  • Page 28 Section 3 • Scheduled Maintenance Procedures September 2016 CHECKLIST B PROCEDURES REV B Models without maintenance-free or sealed 13 Check the ambient air temperature and adjust batteries: the specific gravity reading for each cell as follows: 9 Remove the battery vent caps and check the •...
  • Page 29 Note: For best results, use an extension of adequate size with a length no longer than 50 feet / 15 m. Note: If you have any further questions regarding the battery charger operation, please contact the Genie Service Department. Part No. 227123 3 - 11...

  • Page 30: Inspect The Electrical Wiring

    5 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform Genie specifications require that this procedure be controls. performed every 250 hours or quarterly, whichever 6 Raise the platform approximately 8 feet / 2.4 m...

  • Page 31: Inspect The Tires And Wheels (Including Castle Nut Torque)

    CHECKLIST B PROCEDURES Inspect the Tires and Wheels Test the Emergency Stop (including castle nut torque) Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. A properly functioning Emergency Stop is essential Genie specifications require that this procedure be for safe machine operation.

  • Page 32: Test The Key Switch

    REV B Test the Key Switch Test the Automotive-style Horn (if equipped) Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Genie specifications require that this procedure be comes first. performed every 250 hours or quarterly, whichever comes first.

  • Page 33: Inspect The Voltage Inverter (If Equipped)

    Result: The power tool should operate. There (if equipped) may be a brief (0.5 second) delay if the power tool has not been used in the previous 10 Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever minutes. comes first.

  • Page 34: Test The Drive Brakes

    September 2016 CHECKLIST B PROCEDURES REV B Test the Drive Brakes Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper brake action is essential to safe machine operation. The drive brake function should operate smoothly, free of hesitation, jerking and unusual noise.

  • Page 35: Test The Drive Speed - Stowed Position

    REV B CHECKLIST B PROCEDURES Test the Drive Speed - Stowed Position Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper drive functions are essential to safe machine operation. The drive function should respond quickly and smoothly to operator control.

  • Page 36: Test The Drive Speed - Raised Position

    CHECKLIST B PROCEDURES REV B B-10 Test the Drive Speed - Raised Position Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper drive functions are essential to safe machine operation. The drive function should respond quickly and smoothly to operator control.

  • Page 37: Test The Slow Drive Speed

    REV B CHECKLIST B PROCEDURES B-11 Test the Slow Drive Speed Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper drive functions are essential to safe machine operation. The drive function should respond quickly and smoothly to operator control.

  • Page 38: Test The Flashing Beacons

    B-13 Test the Flashing Beacons Test the Motion Alarm (if equipped) Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Genie specifications require that this procedure be comes first. performed every 250 hours or quarterly, whichever comes first.
  • Page 39 September 2016 Section 3 • Scheduled Maintenance Procedures REV B CHECKLIST B PROCEDURES 6 Press and hold the low speed lift enable button. 15 Press and hold the low speed lift enable button. 7 Press the platform up button and raise the 16 Press the platform up button and raise the platform approximately 1 foot / 0.3 m.

  • Page 40: Perform Hydraulic Oil Analysis

    B-14 B-15 Perform Hydraulic Oil Analysis Inspect the Breather Cap Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Genie specifications require that this procedure be A free-breathing hydraulic tank cap is essential for performed every 250 hours or quarterly, whichever good machine performance and service life.

  • Page 41: Inspect The Electrical Contactor

    Section 3 • Scheduled Maintenance Procedures REV B B-16 Inspect the Electrical Contactor Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the electrical contactor in good condition is essential to safe machine operation.

  • Page 42: Checklist C Procedures

    Replace the Hydraulic Tank Breather Cap - Models with Optional Hydraulic Oil Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first OR when the machine fails to lift the maximum rated load.

  • Page 43: Checklist D Procedures

    6 Activate and hold the platform up toggle switch. 7 Inspect the filter and related components to be sure that there are no leaks. Genie specifications require that this procedure be performed every 1000 hours or annually, 8 Clean up any oil that may have spilled.

  • Page 44: Checklist E Procedure

    4 Tag and disconnect the hydraulic pump inlet hard line and remove the hard line from the Genie specifications require that this procedure be tank. Cap the fitting on the pump. performed every 2000 hours or every two years, 5 Remove the hydraulic tank retaining fasteners whichever comes first.
  • Page 45 September 2016 Section 3 • Scheduled Maintenance Procedures REV A CHECKLIST E PROCEDURE 10 Install the hydraulic pump inlet hard line into the tank. Install the fitting onto the pump and torque to specification. Refer to Section 2, Specifications . 11 Install the hydraulic pump return hard line into the tank.
  • Page 46 Section 3 • Scheduled Maintenance Procedures September 2016 This page intentionally left blank. 3 - 28 Part No. 227123...
  • Page 47 Be sure that all necessary tools and parts are Indicates a potentially hazardous available and ready for use. situation which, if not avoided, Use only Genie approved replacement parts. could result in death or serious injury. Read each procedure completely and adhere to Indicates a potentially hazardous the instructions.

  • Page 48: Platform Controls

    Push in and pull out For further information or assistance, consult the the red Emergency Stop button to reset the Genie Industries Service Department. system. Platform Controls LED Readout Code...

  • Page 49: Circuit Board

    September 2016 Section 4 • Repair Procedures REV A PLATFORM CONTROLS 9 Carefully remove the platform controls circuit board fasteners. Circuit Board 10 Carefully remove the platform controls circuit board from the platform control box. How to Remove the Platform 11 Remove the transparent caps from the platform Controls Circuit Board controls circuit board and save.

  • Page 50: Joystick

    Section 4 • Repair Procedures September 2016 PLATFORM CONTROLS REV A Joystick Platform Controls Alarm How to Remove the Joystick How to Remove the Platform Controls Alarm 1 Push in the red Emergency Stop button to the off position at both the ground and platform 1 Push in the red Emergency Stop button to the controls.

  • Page 51: Platform Emergency Stop Button

    September 2016 Section 4 • Repair Procedures REV A PLATFORM CONTROLS 6 Carefully remove the Emergency Stop base from the Emergency Stop button. Platform Emergency Stop Button 7 Carefully remove the retaining ring from the Emergency Stop button. How to Remove the Platform 8 Carefully remove the Emergency Stop button Controls Emergency Stop Button from the platform control box.

  • Page 52: Ground Controls

    When the ECM is in the set up mode, the ground controls are used to adjust the function speed parameters, machine models, or machine options. For further information or assistance, consult the Genie Industries Service Department. circuit breaker CB2 red Emergency Stop P1 ECM U5...

  • Page 53: Software Revision Level

    September 2016 Section 4 • Repair Procedures REV A GROUND CONTROLS 2 Press the ground controls scroll down button. Software Revision Level Result: The ground controls LED display will indicate the software revision and hour meter information. After 5 seconds, the ground How to Determine the controls LED display will display machine Software Revision Level...

  • Page 54: Machine Setup

    Section 4 • Repair Procedures September 2016 GROUND CONTROLS REV A 1 Turn the key switch to the ground controls position and pull out the red Emergency Stop Machine Setup button to the on position at the platform controls. How to Setup the Machine from 2 Press and hold the ground controls scroll up Ground Controls and scroll down buttons.

  • Page 55: Level Sensor

    September 2016 Section 4 • Repair Procedures REV A GROUND CONTROLS 3 Place the new level sensor onto the level sensor base with the "X" on the level sensor Level Sensor closest to the mast of the machine and the "Y" on the level sensor closest to the steer end of the machine.
  • Page 56 Section 4 • Repair Procedures September 2016 GROUND CONTROLS REV A 4 Install the level sensor adjusting fasteners 7 Turn the key switch to ground control and pull through the level sensor and springs, and into out the red Emergency Stop button to the on the mount.
  • Page 57 September 2016 Section 4 • Repair Procedures REV A GROUND CONTROLS 21 Raise the platform approximately 1 foot / 30 cm. 34 Center a lifting jack under the drive chassis at the non-steer end of the machine. Result: The platform should stop and an alarm should sound.

  • Page 58: Hydraulic Pump

    Section 4 • Repair Procedures September 2016 Hydraulic Pump REV A 4 Activate the platform up function from the ground controls. Function Pump Result: If the pressure gauge reads 3200 psi / 221 bar, immediately stop. The pump The hydraulic pump is attached to the motor which is good.
  • Page 59 September 2016 Section 4 • Repair Procedures REV A HYDRAULIC PUMP How to Remove the Hydraulic Pump Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation.

  • Page 60: Function Manifold

    Section 4 • Repair Procedures September 2016 Function Manifold REV A Function Manifold Components The function manifold is mounted next to the hydraulic power unit. Index Schematic Description Item Function Torque — Coil nut (items E, F and H) ......................5 ft-lbs / 7 Nm Diagnostic nipple ........
  • Page 61 September 2016 Section 4 • Repair Procedures REV A FUNCTION MANIFOLD Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic Part No. 227123 4 - 15...

  • Page 62: Valve Adjustments - Function Manifold

    Section 4 • Repair Procedures September 2016 FUNCTION MANIFOLD REV A 3 Chock both sides of the wheels at the steer end of the machine. Valve Adjustments - 4 Remove the platform controls from the platform. Function Manifold Note: Perform this test from the ground with the platform controls.
  • Page 63 September 2016 Section 4 • Repair Procedures REV A FUNCTION MANIFOLD How to Adjust the 5 Turn the key switch to platform control and pull out the red Emergency Stop button to the on Platform Lift Relief Valve position at both the ground and platform controls.
  • Page 64 Section 4 • Repair Procedures September 2016 FUNCTION MANIFOLD REV A 14 Hold the lift relief valve with a wrench and How to Adjust the Steer Relief remove the cap (schematic item C). Valve 15 While activating the platform up function, adjust Note: Be sure that the hydraulic oil level is at the the internal hex socket clockwise, just until the mark on the hydraulic tank.
  • Page 65 September 2016 Section 4 • Repair Procedures REV A FUNCTION MANIFOLD 4 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls. 5 Activate the function enable switch and press and hold the steer thumb rocker switch to the right.

  • Page 66: Valve Coils

    Section 4 • Repair Procedures September 2016 FUNCTION MANIFOLD REV A Valve Coil Resistance Valve Coils Specification Note: The following coil resistance specifications How to Test a Coil are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air A properly functioning coil provides an temperature, the coil resistance will typically electromagnetic force which operates the solenoid...
  • Page 67 Section 4 • Repair Procedures REV A FUNCTION MANIFOLD How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its coils. Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil.

  • Page 68: Brake Release Hand Pump Components

    Section 4 • Repair Procedures September 2016 Brake Release Hand Pump Components REV A Brake Release Hand Pump Components The brake release hand pump manifold is mounted behind the hydraulic power unit. Index Schematic Description Item Function Torque Hand pump ........J ....Manual brake release ......30 ft-lbs / 41 Nm Needle valve, pilot operated .....

  • Page 69: Hydraulic Tank

    September 2016 Section 4 • Repair Procedures Hydraulic Tank REV A 2 Tag, disconnect and plug the return hard line at the hydraulic filter. Cap the fitting on the filter. Hydraulic Tank Bodily injury hazard. Spraying hydraulic oil can penetrate and The primary functions of the hydraulic tank are to burn skin.

  • Page 70: Steer Axle Components

    Section 4 • Repair Procedures September 2016 Steer Axle Components REV A 7 Tag, disconnect and plug the hydraulic hoses on the drive motor. Cap the fittings on the drive Yoke and Drive Motor motor. Bodily injury hazard. Spraying How to Remove the Yoke hydraulic oil can penetrate and and Drive Motor Assembly burn skin.

  • Page 71: Connections Very Slowly To Allow

    September 2016 Section 4 • Repair Procedures REV A STEER AXLE COMPONENTS How to Remove a Drive Motor 7 Tag, disconnect and plug the hydraulic hoses on the drive motor. Cap the fittings on the drive 1 Block the wheels at the non-steer end of the motor.

  • Page 72: Steer Cylinder

    Section 4 • Repair Procedures September 2016 STEER AXLE COMPONENTS REV A Steer Cylinder Steer Bellcrank How to How to Remove the Steer Cylinder Remove the Steer Bellcrank Note: When removing a hose assembly or fitting, 1 Remove the steer cylinder. See 7-2, How to the O-ring on the fitting and/or hose end must be Remove the Steer Cylinder.

  • Page 73: Non-Steer Axle Components

    September 2016 Section 4 • Repair Procedures Non-steer Axle Components REV A 7 Tag, disconnect and plug the hydraulic hose from the brake. Cap the fitting on the brake. Drive Brake Bodily injury hazard. Spraying hydraulic oil can penetrate and How to Remove a Drive Brake burn skin.

  • Page 74: Platform Components

    Section 4 • Repair Procedures September 2016 Platform Components REV A Platform Platform Extension How to Remove the Platform How to Remove the Platform Extension Deck 1 Disconnect the platform controls from the control cable at the platform, and remove the 1 Remove the fasteners and spring securing the platform controls from the platform.
  • Page 75 September 2016 Section 4 • Repair Procedures REV A PLATFORM COMPONENTS 4 Attach a lifting strap of suitable capacity from an overhead crane and center it around the extension deck railing. Remove the extension deck from the machine. Crushing hazard. The extension deck could become unbalanced and fall when removed from the machine.

  • Page 76: Mast Components

    Section 4 • Repair Procedures September 2016 Mast Components REV A 10-1 4 Tag, disconnect and plug the lift cylinder hose at the function manifold. Cap the fitting. Mast Bodily injury hazard. Spraying hydraulic oil can penetrate and How to burn skin.
  • Page 77 September 2016 Section 4 • Repair Procedures REV A MAST COMPONENTS 5 Remove the fasteners securing the lower rear 10 Using an overhead crane, attach a sling access cover to the chassis and remove the equipped with the appropriate sized hooks to cover.
  • Page 78 Section 4 • Repair Procedures September 2016 MAST COMPONENTS REV A How to Disassemble the Mast 9 Using a drill, carefully drill out the rivets securing the number 2 inner wear pads to the Bodily injury hazard. This bottom half of the number 2 mast section, the procedure requires specific repair number 3 inner wear pads to the bottom half of skills, lifting equipment and a...
  • Page 79 September 2016 Section 4 • Repair Procedures REV A MAST COMPONENTS 10 Attach a lifting strap from an overhead crane 13 Using a drill, carefully drill out the rivets to the mast assembly and carefully rotate the securing the number 4 inner wear pads to the mast 180°.
  • Page 80 Section 4 • Repair Procedures September 2016 MAST COMPONENTS REV A 15 Slide the number 3 mast towards the bottom of 17 Using a drill, carefully drill out the rivets the number 2 mast and align the upper and securing the number 3 inner wear pads to the lower number 3 mast access holes to the upper bottom half of the number 3 mast section.
  • Page 81 September 2016 Section 4 • Repair Procedures REV A MAST COMPONENTS 19 Slide the number 2 mast towards the bottom of 21 Using a drill, carefully drill out the rivets the number 1 mast and align the upper and securing the number 2 inner wear pads to the lower number 2 mast access holes to the upper bottom half of the number 2 mast section.
  • Page 82 Section 4 • Repair Procedures September 2016 MAST COMPONENTS REV A How to Assemble the Mast 5 Attach a lifting strap from an overhead crane to the number 2 mast and carefully slide the Bodily injury hazard. This number 2 mast onto the number 1 mast, with procedure requires specific repair the cylinder mount brackets facing the work skills, lifting equipment and a...
  • Page 83 September 2016 Section 4 • Repair Procedures REV A MAST COMPONENTS 7 Slide the number 2 mast towards the bottom of 11 Using the appropriate rivets, securely install the the number 1 mast and align the lower number upper corner wear pads, to the upper half of the 2 mast access holes to the lower number 1 rivet number 2 mast.
  • Page 84 Section 4 • Repair Procedures September 2016 MAST COMPONENTS REV A 12 Attach a lifting strap from an overhead crane 14 Slide the number 3 mast towards the bottom of to the number 3 mast and carefully slide the the number 2 mast and align the lower number number 3 mast onto the number 2 mast, with 3 mast access holes to the lower number 2 the cylinder mount brackets facing the work...
  • Page 85 September 2016 Section 4 • Repair Procedures REV A MAST COMPONENTS 18 Using the appropriate rivets, securely install the 20 Slide the lower, inner corner wear pads upper corner wear pads, to the upper half of the between the number 4 mast and the number 3 number 3 mast.
  • Page 86 Section 4 • Repair Procedures September 2016 MAST COMPONENTS REV A 21 Slide the number 4 mast towards the bottom of 25 Attach a lifting strap from an overhead crane the number 3 mast and align the lower number to the mast assembly and carefully rotate the 4 mast access holes to the lower number 3 rivet mast 180°.

  • Page 87: Wear Pads

    Working from the lower half of the mast assembly, carefully slide the lift Wear pads on the GRC-12 are used to provide a cylinder into the mast assembly, aligning the uniform fit between the mast sections, as the mast rod ends of the cylinder, to the cylinder mast assembly extends and retracts.

  • Page 88: Lift Cylinder

    Section 4 • Repair Procedures September 2016 MAST COMPONENTS REV A 10-3 Lift Cylinder The lift cylinder is equipped with a normally closed solenoid valve to prevent movement in the event of a hydraulic line failure. How to Remove the Lift Cylinder Bodily injury hazard.
  • Page 89 September 2016 Section 4 • Repair Procedures REV A MAST COMPONENTS 5 Remove the hair pin clips securing the mast cylinder pin to the lower half of the mast assembly. Set the clips to the side. 6 Support the lift cylinder and use a soft metal drift to remove the mast cylinder pin from the lower mast assembly.

  • Page 90: Lift Cylinder Wear Block

    Section 4 • Repair Procedures September 2016 MAST COMPONENTS REV A 10-4 10-5 Lift Cylinder Wear Block Mast Coil Cord How to Remove the Lift Cylinder How to Wear Block Remove the Mast Coil Cord Bodily injury hazard. This Bodily injury hazard. This procedure requires specific repair procedure requires specific repair skills, lifting equipment and a...

  • Page 91: Troubleshooting And Repair Procedures Shall Be Completed By A Person Trained And Qualified On The Repair Of This Machine

    September 2016 Section 5 • Diagnostics Diagnostics REV A Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use. Observe and Obey: Be aware of the following hazards and follow generally accepted safe workshop practices.

  • Page 92: General Repair Process

    Charts describe malfunctions and can aid in troubleshooting the machine by pinpointing the area or component affected. Genie SmartLink Diagnostic System This machine is equipped with the Genie SmartLink Diagnostic System (GSDS). The GSDS indicates a machine malfunction has happened by displaying Operational Indicator Definitions Codes (OIC) and Diagnostic Trouble Codes (DTC).

  • Page 93: Gcon I/O Map

    September 2016 Section 5 • Diagnostics DIAGNOSTICS REV A GCON I/O MAP Ground Wire Gauge I/O Type Controls Circuit Function and Color Pin Number QD31 Connector - Gray QD31-01 ECM Power Power Input 14 RD QD31-02 PCON — E-Stop Power Power Output 18 RD QD31-03...

  • Page 94: Operational Indicator Codes

    Section 5 • Diagnostics September2016 DIAGNOSTICS REV A Operational Indicator Codes Diagnostic Trouble Codes (DTC) (OIC) These codes are generated by the system to indicate that a device or circuit malfunction has These codes are generated by the electrical been detected in the electrical system. system to indicate machine operating status The types of Diagnostic Trouble Codes that may such as Off-level, Chassis Mode Operation and...

  • Page 95: A Troubleshooting "Hxx" And "Pxxx" Faults

    September 2016 Section 5 • Diagnostics DIAGNOSTICS REV A Troubleshooting "HXXX" and "PXXX" Faults The procedure below illustrates typical steps for diagnosing and fixing faults of type "HXXX and PXXX". Diagnostic Chart No Good Check the fault device for a short or open circuit. Replace faulty device.

  • Page 96: Fault Inspection Procedure

    Section 5 • Diagnostics September2016 DIAGNOSTICS REV A Fault Inspection Procedure 5 - 6 Part No. 227123...
  • Page 97 September 2016 Section 5 • Diagnostics DIAGNOSTICS REV A Part No. 227123 5 - 7...

  • Page 98: Type "Hxxx" Faults

    Section 5 • Diagnostics September2016 Type "HXXX" Faults REV A Message on Problem Possible Failure Number GCON LCD Description Causes Mode • Short circuit in platform up #1 harness. H001:COILFAULT Short circuit of the platform up Platform up H001 • Platform up #1 coil short circuit. PLAT UP1:Bat- #1 circuit to battery negative.

  • Page 99: Type "Pxxx" Faults

    September 2016 Section 5 • Diagnostics Type "PXXX" Faults REV A Message on Problem Possible Failure Number GCON LCD Description Causes Mode • Short circuit in switched power #1, down limit Short circuit of the switched P001:PWR FAULT All functions switch, pothole limit switch, digital tilt switch P001 power #1 circuit to battery...

  • Page 100: Type "Uxxx" Faults

    Section 5 • Diagnostics September2016 Type "UXXX" Faults REV A Message on Problem Possible Failure Number GCON LCD Description Causes Mode Short circuit of the GCON main • Short circuit of the GCON main function U001:SWITCHFAULT All GCON functions function enable switch at enable switch.

  • Page 101: Type "Fxxx" Faults

    September 2016 Section 5 • Diagnostics Type "FXXX" Faults REV A Message on Problem Possible Failure Number GCON LCD Description Causes Mode • Short circuit of the down limit switch circuit. All functions F003:SWITCHFAULT Short circuit of the down limit F003 •...

  • Page 102: Type "Cxxx" Faults

    Section 5 • Diagnostics September2016 Type "CXXX" Faults REV A Message on Problem Possible Failure Number GCON LCD Description Causes Mode C001:GCON ECM • Incorrect software file. All functions GCON ECM CRC check error. C001 FAULT TYPE 1 • GCON ECM internal failure. inhibited.
  • Page 103 September 2016 Section 6 • Schematics Schematics About This Section There are two groups of schematics in this section. An illustration legend precedes each group of drawings. Electrical Schematics Observe and Obey: Electrocution/burn hazard. Contact with electrically charged circuits Troubleshooting and repair procedures shall be could result in death or serious completed by a person trained and qualified on injury.

  • Page 104: Electrical Component And Wire Color Legends

    Section 6 • Schematics September 2016 Electrical Component and Wire Color Legends REV B ELECTRICAL COMPONENT LEGEND ELECTRICAL COMPONENT LEGEND cont. Item Description Item Description Battery Resistor Circuit breaker, 7A R27 = Resistor 25 Ohm, 25W (QS retail) R30 = Resistor, 200 Ohm, 10W CON1 Contactor, Motor controller power, NOHC Level sensor...

  • Page 105: Wiring Diagram - Ground And Platform Controls

    September 2016 Section 6 • Schematics Wiring Diagram Ground and Platform Controls REV B Part No. 227123 6 - 3...

  • Page 106: Electrical Symbols Legend

    Section 6 • Schematics September 2016 Electrical Symbols Legend REV B Limit switch Motor controller Key switch Emergency Stop button Wire with description or color Solenoid valve with diode Motor Circuit breaker Circuits crossing no connection Level sensor Fuse Battery charger Diode Horn or alarm Deutsch connector...

  • Page 107: Electrical Schematic (From Serial Number Grc11-1000 To Grc11-1078)

    Section 6 • Schematics September 2016 Electrical Schematic • (from serial number GRC11-1000 to GRC11-1078) 6 - 5 6 - 6...

  • Page 108: Electrical Schematic (From Serial Number Grc11-1079)

    Section 6 • Schematics September 2016 Electrical Schematic REV C • (from serial number GRC11-1000 to GRC11-1078) 6 - 6 Part No. 227123...
  • Page 109 September 2016 Section 6 • Schematics REV C Electrical Schematic • (from serial number GRC11-1000 to GRC11-1078) Part No. 227123 6 - 7...
  • Page 110 September 2016 Section 6 • Schematics Electrical Schematic • (from serial number GRC11-1000 to GRC11-1078) 6 - 7 6 - 8...
  • Page 111 Section 6 • Schematics September 2016 Electrical Schematic • (from serial number GRC11-1079) 6 - 9 6 - 10...
  • Page 112 Section 6 • Schematics September 2016 Electrical Schematic REV D • (from serial number GRC11-1079) 6 - 10 Part No. 227123...
  • Page 113 September 2016 Section 6 • Schematics REV D Electrical Schematic • (from serial number GRC11-1079) Part No. 227123 6 - 11...
  • Page 114 September 2016 Section 6 • Schematics Electrical Schematic • (from serial number GRC11-1079) 6 - 11 6 - 12...

  • Page 115: Hydraulic Component Reference And Symbols Legend

    September 2016 Section 6 • Schematics Hydraulic Component Reference and Symbols Legend REV A Orifice Check valve Brake Variable speed motor Solenoid operated Fixed displacement pump Hydraulic cylinder 3 position 4 way directional valve Solenoid operated 2 position 4 way directional valve Bi-directional motor Solenoid operated...

  • Page 116: Hydraulic Schematic

    Section 6 • Schematics September 2016 Hydraulic Schematic REV B CALL-OUT LEGEND Item Description Test port Check valve, steer circuit Relief valve, lift Check valve, brake circuit Drive forward/reverse Steer left/right Flow regulator/relief valve Platform up Relief valve, system Hand pump, manual brake release Check valve, manual brake release Platform lowering valve Orifice, platform down circuit...

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